Re: '57 Ford Custom 300 Tudor Sedan
 

What color are you looking at for the 57?....

Re: '57 Ford Custom 300 Tudor Sedan
 

I've been agonizing over that, Dan. I'd planned for a long time to two tone it with silver on top and a medium to dark grey on the bottom. I used the original gold inserts as patterns for a real nice black/grey carbon fiber vinyl to go between the stainless. However, I haven't come up with a good way to do the break between the colors away from the trim. I'm not real fond of the factory scheme but for the life of me, can't come up with much better. If inspiration doesn't strike soon, it may wind up the same solid color as the 68 silver truck. The frame, suspension and engine are all done in various shades of silver and grey, so black, grey, silver and etc. are all possibilities.

Re: '57 Ford Custom 300 Tudor Sedan
 

With a quick search I found a few images of two-tone 57's. I'm just not sure what your trim looks like. You may have seen these already, but just in case...

Brochure or ad for the 300
http://www.oldcarbrochures.com/stati...rochure-02.jpg
http://www.regresspress.com/catalog-..._300_id920.jpg

And a feature car on another website (says it's a fairlane 500 though.)
http://www.cruisenewsonline.com/1957...00Feature.html

Re: '57 Ford Custom 300 Tudor Sedan
 

Thanks, Duane. My trim runs the full length of the side like below. My dilemma is that I've filled all the seams, front and rear, so there are no natural dividing lines. Plus I never liked how the tail light housing was one color and the quarter panel another. Up front, the factory scheme accentuated the "bug eyed" look by having the lower color surround the headlights up to the eyebrow. I do like the look of the Fairlane 500 up front, though. I'm reluctant to have long stretches of the parting line between the colors exposed. A very thin pinstripe might work to hide the break. Just need to think on it some.

Re: '57 Ford Custom 300 Tudor Sedan
 

Hate to hear the news on the pickup but I am glad to see the thread on the 57. I enjoy watching how you approach and solve problems. Good instruction.

Dwight

Re: '57 Ford Custom 300 Tudor Sedan
 

OK Vic ... I'm game. The 300 '57 is on my list of one of the best looking cars EVER.

I've always had an affection for post cars ... having had 3 chevy 2 sedans & 2 Fairlane sedans. I am also on a trek to complete my '64 fairlane right now. It's a bit more race carish with a complete tube frame, struct front & 4 link rear but plans are for street duty.

I'll follow along.

R 46

Re: '57 Ford Custom 300 Tudor Sedan
 

Found the link and subscribed! Thats one sweet project!

Re: '57 Ford Custom 300 Tudor Sedan
 

Thanks, guys! Great to have you along for the ride.

The firewall was fairly complete, so I moved around the corners and cleaned up the cowl areas below the A-pillars. To make room for the Vintage Air suitcase, I had to remove the rain gutter area of the cowl. This left a large area open adjacent to the windshield wipers. I welded in patches to close it up as well as the rain channel ports on both sides of the cowl. No water allowed inside. After the bodywork was done on the entire cowl / firewall I applied sound deadener to the underside of the roof. This helped quite a bit while doing bodywork on the roof. By now it is mid 2006 and I was about ready to drop the body back on again to finish the trunk area and exhaust hangers.

Re: '57 Ford Custom 300 Tudor Sedan
 

I'll bet nobody chem dips in Washington do they... Wish i had the option to concider..

Re: '57 Ford Custom 300 Tudor Sedan
 

Yeah, the guys doing chemical stripping ...and chroming ...and plating have had to clean up their act over the last couple of decades. Nearly everything they use is now regulated as hazardous. Takes a lot of dedication to stick with it and many have gone by the wayside.

On a similar note, a few years ago in MO they passed a law that requires salvage yards to have a title for all cars they're parting out. Apparently there's no grandfather clause. A lot of yards with old classic cars couldn't meet the requirement, so they're crushing the cars and selling them for scrap. My custom bumper setup on the Ford wasn't developing the way I'd hoped, but I had a plan B that involved acquiring a front valance off a '59 Plymouth. Put out feelers and have had no luck. I wasn't aware of the issue until just recently. Guess it's the law of unintended consequences.

Re: '57 Ford Custom 300 Tudor Sedan
 

The body went back on the chassis briefly while I built out the trunk floor and fixed the exhaust hangers. I had mounted the fuel tank under the trunk but to do so and keep it from hanging down and showing below the rear bumper, I had to raise the trunk floor a couple of inches. It'll still haul a lot of luggage. ;)

Re: '57 Ford Custom 300 Tudor Sedan
 

Clean ... right down to the dzus panel for the battery(?)

Re: '57 Ford Custom 300 Tudor Sedan
 

Yes, I relocated the battery to the rear for better weight distribution. I may need the space it occupied up front for the A/C dryer or some other components. Not sure just yet.

From mid 2006 to early 2007 I intermittently did bodywork. The body shell was back on the rotisserie for the last time as I did extensive repairs to the roof, quarter panels and etc. Filled all the seams and applied Zolatone to the trunk, firewall and underside. It's a spatter paint that is relatively tough. The inside of the tubs got undercoated as well.

Re: '57 Ford Custom 300 Tudor Sedan
 

Fantastic! Only eight years to go :lol:

Re: '57 Ford Custom 300 Tudor Sedan
 

there is a place in Oregon that will pick up. $3200.00 :eek:
I spent 1300 back in the eighties when I dipped a Chevelle at Kelso Chemstrip. Couldn't sleep that night I spent soooo much money. LOL

Vic1947, love the build!

Re: '57 Ford Custom 300 Tudor Sedan
 

Yeah, just like flying a plane, John ...hours on end of absolutely nothing happening interspersed with a few moments of terror filled activity.
Thanks! I generally lose the most sleep when I pay good money and get hosed. But I've never regretted paying a premium price for a great job.

Below are a few shots from March 2007. Body is going on the frame for the last time. With a little help from my friends it made it without boogering anything up. Raised the body up high enough to roll the chassis under it. When the chassis was in the right place we started to lower the body onto it.

Re: '57 Ford Custom 300 Tudor Sedan
 

Hit one minor snag toward the end. The sides of the tubs needed to slip down along the frame. Had never put the body back on after doing the trunk floor and it was a little tight. We were able to tweak it just enough to get it to drop the last little bit. Hope I never need to remove it again. Starting to look like an actual car.

Re: '57 Ford Custom 300 Tudor Sedan
 

HOw did I miss this? I've seen this car in person, and it looks bad azz just sitting there. Can't wait to see it going forward! Yee-haw!

Re: '57 Ford Custom 300 Tudor Sedan
 

Hey Vic... Are you making any headway????

Re: '57 Ford Custom 300 Tudor Sedan
 

Oh, yeah! I've got a lot to post once I get caught up to the present, Dan. But it wouldn't make much sense to leave any more gaps in this build than occurred naturally. ;)

Re: '57 Ford Custom 300 Tudor Sedan
 

I'm liking this! Your ability to share the build matches your ability to build. Keepem coming Vic!

Re: '57 Ford Custom 300 Tudor Sedan
 

Got ya... I love looking at the history... I was excited to see how far along you have gotten... T-Minus 5 months... lol

Re: '57 Ford Custom 300 Tudor Sedan
 

Thanks, John. My main limitation is pictures ...didn't take as many as I should have. At least I finally scanned them in and put them in order - thinking maybe I'd do a website one day. Little did I know that forums would develop the way they have. Makes it a lot easier on us old timers.
[Groan] I'm all about the time crunch now. Lately, I've been going back down to the shop after supper for a couple of hours in addition to my daily routine. Only do the forum during breaks or early / late. However, I'm very nearly caught up.

By mid 2007 we'd acquired a fifth wheel RV and for the next three years very little got done on the Ford. I inventoried all my stainless trim and hand delivered a single piece to two different restorers as a test. The one shop did an excellent job and was very prompt. The other guy took 6 months for one piece of trim and then shipped it via UPS in a FedEx box. It was delivered folded in half. To add insult to injury, the dipsh!t didn't insure it for enough to cover a new one. So I located another restorable piece in Oregon and shipped it and the rest of the stainless to Vintage Vehicles in WI. They did a fabulous job and just to be safe, we drove to WI to pick it up.

I also discussed a custom front end design with my buddy Steve. He and his cousin Charles Smith whipped out an old school approach and sent me a sketch. Later on, Charlie updated it in PhotoShop and sent me several rendering with different headlight suggestions. I began the search for the parts I needed and was able to acquire all of them over the next few years.

Re: '57 Ford Custom 300 Tudor Sedan
 

Dude.. I love that old school custom look of the front...

I am looking to do the 63-67 Corvette touch to the front of "Class Act"

Re: '57 Ford Custom 300 Tudor Sedan
 

Across those years, there's a wide range of possibilities, Dan. Interested to see what you come up with.

Re: '57 Ford Custom 300 Tudor Sedan
 

I was looking forward to seeing the 67 on the power tour, but I can tell this 57 is going to be awesome. Love looking through your builds, your attention to detail is something else. Hopefully see you in June somewhere along the Tour. Dave

Re: '57 Ford Custom 300 Tudor Sedan
 

We pulled up stakes late 2009, moving from TX to KC. The Ford would sit for another year before it got some love. My dislike of the headers had continued to grow to the point I could no longer abide them. The key factor was the stock steering sector. I revisited the power rack and pinion conversion and found an individual that was selling a kit. I ordered one and when it arrived I pulled the engine and got busy with the swap. Regrettably, I don't have a lot of pictures of the final product, but it served it's purpose which was to free up the space to build a new set of headers.

Years ago, in anticipation of this moment, I asked good buddy Shaun Sublet to CNC some stainless header flanges for the 460. I also purchased the stainless U-bends and collectors to build the new set. I dug thru the dusty cardboard boxes that were slowly disintegrating on my shelves and found the long lost treasure. I'd done a few tubes before, but never a full set. You start with flanges on one end and collectors on the other and thin air in between. I'm not a fanatic about equal length, but I still wanted to keep the primaries as close to equal as was reasonable. I'd watched John Harrison build headers in his shop, so I knew the basics. Never, ever, miter a joint ...always cut perpendicular to the tube. Use teeny, tiny ticky tacks to join the tubes because you're going to make mistakes and have to break them apart. The longest tube should be the straightest and the shortest will have the most switchbacks. Plan ahead, plan ahead, plan ahead.

Welding thin stainless tubing is a bit of an art form, but it's a lot easier if you purge the tubes with argon. I picked up a handy little gadget that fits in one end of the tube and some special aluminum tape to seal off the other end. Punch a tiny hole in the tape, turn on the gas and watch the magic. Doing it like this results in a nice clean weld with no sugaring and uses minimal filler rod.

Re: '57 Ford Custom 300 Tudor Sedan
 

Looks like artwork. You got some real skills.

Re: '57 Ford Custom 300 Tudor Sedan
 

You may have noticed the engine has a new look. While it was out and the rack and pinion steering was being installed, I decided to tear it down again (third time) and address some nagging issues. The rods were stock Ford forged units with ARP bolts and had been shotpeened and the side beams ground. I had used a rod bolt stretch indicator to torque them and was uncomfortable with the procedure. So I bought a new set of forged H-beam rods and swapped them in.

Also, the cast iron heads had been ported and the exhaust floors raised for improved flow. In order to convert an oval exhaust port to a D port, I had to insert a stainless "tongue" into each one. To attach them, I had to mill a pocket in the head, then drill and tap holes for countersunk screws. Most of the tapped holes went into the water jacket. I used a high temp adhesive sealant but was concerned it might come back to haunt me. So I anted up and got a set of aluminum heads to replace them. Problem solved, plus they look nicer and weigh a whole lot less. I repainted the valve covers in the colors I planned to use on the rest of the car. Steve arranged for a shop he uses to laser cut some stainless trim pieces to match the trim on the sides of the body. Added them to the covers, which by the way, are an old set of M/T finned aluminum pieces I milled down and re-contoured.

A video of the engine assembly can be seen here at 460 Ford Build.

Re: '57 Ford Custom 300 Tudor Sedan
 

You bet, Dave. It may not be 100% but we're going anyway.
Thanks, Russell.

Re: '57 Ford Custom 300 Tudor Sedan
 

I love 57 fords! This one is looking real smooth just like you want. I'm in for this

Re: '57 Ford Custom 300 Tudor Sedan
 

Thanks, good to have you along!

After finishing up the headers, I tinkered around with the interior and the doors. When I bought the car it came with two instrument clusters. I gutted one and with some help from my machinist mentor, Bruce Wilson, I modified the housing and built an insert to hold a complement of VDO gauges. Like a lot of my parts, it sat in a box for years. Finally though, I settled on the look I wanted and covered it with a carbon fiber print vinyl I found online. Made inserts for the dash to hold the radio and a/c vents but they still need some more engineering. I also started the process of laying down the sound deadener.

Fitted the doors with power windows and shaved the door handles and lock assemblies. Still need to finish installing the pop locks. Revised the floor shifter and steering column, finalized the fuel system and modified the core support for the larger aluminum radiator. Lots of other things have happened as well ...converting the wipers to electric, throttle linkage to cable style and relocating the battery to the trunk.

In May of 2011, I purchased the 68 Stepside. By July, I couldn't hold off any longer and began a year and half frame off build. Needless to say, the Ford project was once again shelved. After finishing the silver truck, I assembled the front clip for the Ford and set it in place for the first time in over twenty years. Then along came CRLS and once again the Ford took a back seat.

Fast forward to Jan 1, 2015 and welcome to the final push. We need to be rolling in five months, so hang on.

Re: '57 Ford Custom 300 Tudor Sedan
 

Vic.. I really like the Gauge setup... the gap issue on the "B" pillar could be a bit of a issue... LOL Man I can't wait to see this thing running...

Re: '57 Ford Custom 300 Tudor Sedan
 

Hey, Dan, the door gap looks worse in the photo than it does in person, but it will require a little finesse for sure. The gaps on the other three sides look good, so all the work will be on the back edge.

If you can't wait to see it running, imagine me. 25 years, 5 different homes, 4 times off and on the chassis, 3 sets of tires, 3 engine rebuilds, 2 sets of headers ....and it has never once fired up or turned a tire under its own power. I'm past ready for it to come to life. :lol:

Re: '57 Ford Custom 300 Tudor Sedan
 

Gorgeous, as always. Eagerly await the next installment. As always, if you need anything, call.

Re: '57 Ford Custom 300 Tudor Sedan
 

I can only imagine... I am going crazy after almost 4 years on "Class Act" and I am at least 1 more year and probably 2...

Re: '57 Ford Custom 300 Tudor Sedan
 

On New Years Day, Scott came over and helped us move CRLS to the upstairs garage and then roll the '57 into the workshop. The immediate goal was to get the front clip mods done so I could remove the parts and get them to George at Eagle Stripping. Schedule is to have the car at Precision Collision no later than the first of March. So the final bodywork and fitment has to happen quickly.

First on the list was frenching in the headlights. No matter what I end up with for a bumper, the bug eyes had to go. AutoLoc makes a headlight frenching kit that has the buckets and the rings, but I already had '56 Ford truck headlight rings. Their kit costs around $350 which made me gulp a little bit. In the end I reasoned I could make my own buckets for just a few bucks if I carefully cut out the stock mounting surface and moved it back the amount needed. So I measured the diameter, made a template and transferred it to the mounting pad on the fender. Used an air saw with a thin kerf, fine tooth blade to cut it out. I estimated that a 2" recess would be about right, so I took some 2" wide sheet metal strips and formed them around one of my welding cylinders and spot welded them into a ring.

Re: '57 Ford Custom 300 Tudor Sedan
 

Tacked the mounting plate I'd removed and cleaned up to the back of the ring I made and test fit it into the hole. Turned out that a 2" recess wasn't quite enough. The headlight protruded thru the ring a bit too much, plus the back of the ring was almost touching the adjustment screws. If I left it as it was, the trim ring could interfere with the hardware. So I decided to add a 3/8" strip to the ring which made it fit just right.

Re: '57 Ford Custom 300 Tudor Sedan
 

Niice Vic... Love the frenched look .. back in the day this is how they did it so buying a 350.00 kit would really have been unnecessary considering your talents...

Re: '57 Ford Custom 300 Tudor Sedan
 

All amazing work, clean or detailed just don't describe it. Love the 2 minute blueprint build and the headers are freakin' awesome!!
So here we are, up to date and maaaaaan you got some work ahead Vic. We're all rootin for you!